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1
Large Kaplan Units case study Xayaburi
Introduction:
The Xayaburi project is a hydroelectric power project on the Mekong River in Laos. To
ensure the best possible commercial use of this hydropower potential, it is necessary to
develop very large and powerful Kaplan turbines. In addition, this river is home to a large
population of fish, which has been found to be particularly worth to protect.
ANDRITZ HYDRO GmbH was awarded the contract for the supply of electromechanical
equipment for hydroelectric power plant. For this project, an impeller was developed, which
must meet the specific requirements of the project. The result of this research is the design of
a low-speed Kaplan turbine, which is regarded as particularly fish friendly.
The following table shows all important data from the large EGAT- and the small EdL-units:
Table 1 Main data
Main data:
Turbine type
Direction of rotation
Synchronous speed
Maximum net head
Rated net head
Minimum net head
Number of runner blades
Number of guide vanes
Maximum turbine power
output
Minimum Discharge
Maximum Discharge
Runner diameter
Annual energy
Unit 1-7
EGAT
Kaplan, vertical
Counter clockwise
83.33 rpm
39m
28.5m
17.3m
5
24
186.6MW
Unit 8
EdL
Kaplan, vertical
Counter clockwise
150 rpm
39m
28.5m
17.3m
5
24
68.8MW
210m/s
725m/s
8.6m
7190.5GWh
72.6m/s
267.0m/s
5.05m
576.9GWh
The main focus in the runner development is to ensure high efficiency and excellent
cavitation behaviour across the whole operation range. The runner development was carried
out using Computational Fluid Dynamic (CFD).
CFD has become a major simulation tool for the development of axial turbines in recent
decades, the application ranges from feasibility studies and design optimization to simulations
of complex unsteady flow phenomena. The flow simulation also gives the information of the
impact of the flow on the runner structure and enables reliable life time predictions.
A hydroelectric power plant is designed with a very high level of efficiency, the very high
head range with simultaneously high flow rate variations. Fig 1 shows the comparison of the
operating range of Xayaburis EGAT and EdL Kaplan 5-blade turbines (blue lines) to other
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Large Kaplan Units case study Xayaburi
recent Kaplan projects (red lines) by means of dimensionless discharge and dimensionless
head, which shows that the operating range for the Xayaburi project is very large compared to
other projects. The dimensionless discharge q11, and the dimensionless head n11 are defined
as:
n 11
Q11
nD
H
Q
2
D H
where n is the speed of the turbine, D is the runner diameter, H is the head and Q is the
discharge.
Fig. 1 Comparison of operating range (blue lines Xayaburi operating range, red lines
operating range of other recent Kaplan projects)
After the development of individual hydraulic components, the combination of all the parts is
carried out in order to fine-tune the overall hydraulic system. The model test is performed as a
step-by-step process, from which an ideal design solution for the Xayaburi project could be
achieved.
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Large Kaplan Units case study Xayaburi
simulations can be applied to monitor the extension and intensity of shear layers in the flow
field.
Modern high performance runners generally have a very low turbulence level. Further
minimization of turbulence is the primary target of every new turbine development in order to
improve the fish-survival rate, decrease noise level and reduce energy losses.
High precision in manufacturing the components allows reducing the gaps between blades
and housing, thus reducing water flow through those gaps and subsequent turbulences.
Overall survival rates are strongly depending on the power plant head and on the fish
population. Migratory fish periodically swim upstream or downstream of river courses to
reach their spawning fields. Fish that are migrating upstream do swim against the natural flow
of the river. Therefore fish need to be guided across the barrage through attraction flows,
indicating the entrances to the upstream fish migration facilities provided by the project (see
Fig.2). Fish that are migrating downstream do move with the flow of the river. Those fish
which do not pass through the bypass system and are small enough to pass the upstream fish
screens will cross the barrage with the river flow through the turbines.
The main cause for fish mortality is when fish get in contact with one of the stressors
(measurable, physical quantities that can be linked to each injury mechanism like e.g. absolute
pressure, vorticity or strain rate, velocity and pressure fluctuations, impact intensity,...) while
passing the turbine. Fish friendly turbine designs minimize the probability for fish to get
affected by mortality causes and therefore increases the survival rate of fish.
The oil free hub design has a major positive impact on the water quality and thus on the
environment compared to the traditional design. For Xayaburi, the oil free hub concept will
be applied and saves about 14.000 litres of oil per unit.
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Large Kaplan Units case study Xayaburi
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Large Kaplan Units case study Xayaburi
Fig. 5 Optimization objectives (f1) and (f2) related to the impeller outflow, hence
defining the draft tube feeding: (f1) and (f2) are defined as the deviation of kcm(r) and
kcu(r) with respect to a user defined targetdistribution. [11]
Fig. 6 Optimization objectives (f3) and (f4), related to the blade pressure distribution:
(f3) expresses the standard deviation of the blade loading and (f4) is defined as the
minimum of all - profiles and controls incipient cavitation. [11]
In this work, the design-optimization is carried out at three operating points: the best
efficiency (optimum), the full-load and a part-load point. So, eventually, the four objectives
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Large Kaplan Units case study Xayaburi
(F1, F2, F3 and F4) to be minimized are the weighted sums of f1, f2, f3 and f4 at the three
operating points,
3
Fi
w j fi
OPj
j 1
where i = 1,2,3,4 denotes the objective and j = 1,2,3 the operating point. In the above
equation, wj are appropriate weights that denote the importance of each operating point.
The runner geometry is parameterized by superimposing a predefined thickness distribution
onto a parameterized mean camber surface. The parametrized profiles of hub and shroud are
given and the stator blades are fixed. The runner has 5 blades.
Level 2: In a second step the most promising pre-optimized variants are checked using more
detailed CFD simulations. 3D-Navier-Stokes simulations are carried out for the same set of
operating points as in the first step. Contrary to Level 1 the flow simulations now include the
gaps at the hub and at the blade tip as well as the guide vanes in order to simulate realistic
runner inflow conditions. As in Navier-Stokes simulations friction and turbulence effects are
taken into account, the runner efficiency can be used as additional objective to further reduce
the set of promising variants, which then are usually passed to the 3rd optimization level.
Level 3: In the third optimization step 3D-Navier Stokes simulations including the draft tube
are carried out for a number of operating points on a propeller curve which is chosen firstly,
to represent the most important operating conditions and secondly, to confirm the fulfilment
of the performance guarantees.
Kaplan turbines operate under almost optimal conditions in the entire operating range.
Therefore, steady-state CFD is a reliable method for the design of double regulated turbines.
Nevertheless, every CFD model has to be set up properly to achieve accurate and reliable
solutions and the possible sources of error are manifold. For more information see the
ERCOFTAC Best Practice Guidelines [ref.2]. Various investigations show that, depending
both on the numerical parameters of the computation and on the respective operating point,
the uncertainty of efficiency prediction may range from 1% to 10%. See for example [ref. 3]
which aims at a precise prediction of the pressure field in a Kaplan runner in order to assess
the quality of a turbine design regarding fish survival. It is also well known and documented
that CFD simulations of decelerated flow and draft tube flow in particular involve
considerable uncertainties. In a recent publication [ref. 4] presented a propeller turbine flow
simulation in comparison to detailed model test measurements. Elaborate time dependent
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Large Kaplan Units case study Xayaburi
CFD simulations were needed in order to realistically predict the flow features in the draft
tube in that case.
The runner design for the EGAT runner is obtained by the normal AH design procedure and
the EdL runner was obtained by the support of an automatic optimizer.
Consequently performance guarantees of Kaplan turbines can be estimated on basis of
thoroughly validated and carried out CFD simulations but as emphasized before CFD
simulations cannot serve as proof of guarantee.
For Kaplan turbines, which usually are characterized by relatively low head and high
discharge, the most accurate way to determine the turbine efficiency is a fully homologous
model test. While the measurement tolerance for efficiency at the test stand is approximately
0.25%, the tolerance of prototype tests is around 2%. A model test furthermore gives the
possibility to investigate the cavitation behaviour of the turbine thoroughly and to measure
additional values such as axial thrust and runner blade as well as guide vane torque.
While CFD is a very valuable tool for turbine design and the backbone of hydraulic water
turbine development, a CFD based runner development of a Kaplan turbine remains
challenging and numerical flow simulations cannot serve the purpose of a proof of guarantee.
This is a main reason for the need of model tests.
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Large Kaplan Units case study Xayaburi
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Large Kaplan Units case study Xayaburi
During the homologous model test campaign, tests regarding efficiency, cavitation, runaway
speed, pressure fluctuations, axial thrust, guide vane torque and runner blade torque were
performed. Prior to all tests the measuring devices were calibrated with certified normals. For
determination of the model efficiency the values of head, flow, torque and speed of the model
turbine have to be measured. With head and flow the input power can be calculated, with
torque and speed the output of the turbine. The ratio between these values gives the efficiency
of the model turbine as an absolute value derived from direct measurement.
For efficiency testing so called propeller curves are produced by varying the wicket gate angle
while keeping the runner blade angle and the speed factor nED constant (see Fig 10). This is
done for several runner blade angles per speed factor (see Fig 11) and for several speed
factors. By means of these propeller curves for different nED values the model hill chart QED
versus nED can be plotted with lines of constant efficiency, wicket gate angle and runner blade
angle.
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Large Kaplan Units case study Xayaburi
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Large Kaplan Units case study Xayaburi
Index-Tests
It is very difficult and expensive to accurately measure absolute efficiencies on most of the
horizontal and vertical Kaplan type power plants. Usually the measurements fail at the
determination of the discharge of one unit which is the key for absolute measurements, except
for special cases like the thermodynamic method. As written in relevant literature this is not a
trivial task. (IEC 60041, 1991)
An index test is not an absolute method. According to IEC 60041:1991 standard test code
chapter 15 the index test is a secondary measuring method to determine relative quantities of a
turbine.
The discharge is only measured as a proportion of an indexed value. An indexed value is an
arbitrary scaled value. The scaling can be determined by relating the index value to the data
from a model test. The model test itself is only relative to the prototype. Therefore the values
obtained from an index test remain relative to the real discharge and all other parameters of
the performance test, calculated from the discharge, are relative too.
IEC 60041-1991 standard test code states clearly that absolute values including efficiencies
cannot be determined with the index test but by accepting the nature of the index test as a
relative measurement and available model test data are a very good tool to compare and verify
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Large Kaplan Units case study Xayaburi
the performance as needed. Index tests are foreseen in order to determine the main power
parameters and the optimal wicket gate/runner blade relationship.
Status on Site
The construction work is already in progress since 2012. At first the first stage cofferdams
and the intermediate block wall, which separates the spillway and the navigation lock from
the main powerhouse, were built (see fig 14).
Conclusion
In this paper the design aspects of a large Kaplan turbine using Xayaburi power plant as a
case study in terms of fish friendliness are described in detail.
Xayaburi HPP is located at the Mekong in Laos. ANDRITZ HYDRO was awarded in 2012
from CH. Karnchang (Lao) Company Ltd. to supply the electromechanical equipment for the
Xayaburi run-of-river hydropower station including all the EM equipment including 7 large
Kaplan turbines with a maximum turbine power output of 186.6MW each and one small
Kaplan turbine with a maximum turbine power output of 68.8MW.
The hydraulic design was carried out using numerical flow simulation (CFD) together with
modern optimization software (EA) and these results where then compared during the
development process with model test data.
Two fully homologous model acceptance tests were performed in the hydraulic laboratory in
Linz in 2013, which is the first major project milestone.
Construction on site is ongoing and the project is scheduled for full completion (COD) by
October 2019.
Acknowledgement
The authors would like to thank XAYABURI Power Company Limited for permission to
publish this paper. Special thanks are expressed to Dr. Michael Raeder for his valuable
support during the preparation.
References
1. Keck H., Sick M., 30 years of numerical flow simulation in hydraulic turbomachines, Acta
Mechanica, 2008
2. Casey M. V., Wintergerste T., Best Practice Guidelines for industrial CFD, Published by
ERCOFTAC, 2000
3. Sick M., Liang Q., Ebner L. L., Kiel J.D., A further step towards CFD based assessment of fish
survival in a Kaplan hydro power station, Proceedings of the Water Power Conference, Spokane,
Washington, U.S.A., 2009
4. Vu T.C., Gauthier M., Koller M., Dechnes C., Flow simulation and efficiency hill chart
prediction for a propeller turbine, 25th IAHR Symposium on Hydraulic Machinery and Systems,
Timisoara, Romania, 2010
5. Mauricio Formaggio et al.: Future of Low Head Turbines Concerning Environmental Aspect,
Hydro Vision Brasil, Sao Paulo, Brasil, 24-26 September 2013.
6. A. Gehrer, R. Schmidl, D. Sadnik, 2006, Kaplan Turbine Runner Optimization by Numerical
Flow Simulation (CFD) and an Evolutionary Algorithm, Proceedings of 23rd IAHR Symposium
Yokohama
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Large Kaplan Units case study Xayaburi
7. Gehrer, A., 1999, "Entwicklung eines 3D-Navier-Stokes Codes zur numerischen Berechnung der
Turbomaschinenstroemung"
Dissertation
Technical
University
Graz,
http://www.ttm.tugraz.at/arno/arno-paper.html
8. Gehrer A., Panzenboeck R., Schmidl R., Hassler P., Runner-Replacement Study of a Vertical
Kaplan-Turbine, Proceedings of 13th Intern. Seminar on Hydropower Plants, Vienna 2004
9. Gehrer, A., Benigni, H., Kstenberger, M., Unsteady Simulation of the Flow Through a
Horizontal-Shaft Bulb Turbine, Proceedings of the 22nd IAHR Symposium on Hydraulic
Machinery and Systems, June 29 July 2, 2004 Stockholm
10. EASY: http://velos0.ltt.mech.ntua.gr/research/easy.html, http://147.102.55.162/EASY/
11. Arno Gehrer, Irida Skouteropoulou and Richard Kellner, "Runner Development for the YBBS
2020
Rehabilitation
Project
at
Ybbs-Persenbeug
Power
Plant
in
Austria",
WASSERWIRTSCHAFT EXTRA 2015
Maria Elisabeth Collins graduated in Aviation at the University for Applied Sciences in Graz/Austria
and wrote her diploma thesis at EADS Germany GmbH in 2006. Between 2008 and 2011 she worked
as a research assistant at the Institute for Thermal Turbomachinery and Machine Dynamics at the Graz
University of Technology, and gained much knowledge in turbulence and transition modelling. She
obtained her PhD of engineering sciences at the Graz University of Technology in 2013. Since 2012
she is working as a design engineer at ANDRITZ HYDRO GmbH Linz.
Luisa Lameiro graduated in civil engineering from FEUP Faculdade de Engenharia da Universidade
do Porto in 2009. After her studies she did an internship at EDP Energias de Portugal in Porto
(Portugal) and since 2010 she is employed by ANDRITZ HYDRO as hydraulic engineer at the
hydraulic laboratory located in Linz, Austria. She is responsible for hydraulic development projects
and model testing.
Thomas Eiper holds a Master Degree in Mechanical Engineering and Business Administration from
the University of Technology in Graz, Austria. He started his career in 2007 as a Test Rig Engineer at
VA TECH HYDRO in Linz, Austria. For a period of one year he attended and conducted semi and full
homologous model tests of radial and axial turbines. After one year at the hydraulic laboratory in Linz
he changed to the hydraulic layout department of ANDRITZ HYDRO in Linz, Austria. He is
responsible for hydraulic layouts of all types of turbines. Beside his main profession he collaborates in
several Research and Development projects within ANDRITZ HYDRO.
Irida Skouteropoulou graduated from the National Technical University of Athens, Greece in 2010,
with a specialization on automatic optimization field. After completing her internship in ANDRITZ
AG in the Hydraulic design and Computational Fluids Dynamics Department in Graz, Austria, she
joined the CFD Group as a hydraulic designer and an automatic optimization expert till 2014.
Arno Gehrer is a research engineer at ANDRITZ AG since 2001. He obtained his Ph. D. in
mechanical engineering from the University of Graz in Austria, where he had been working as
research assistant and assistant professor at the institute for thermal turbomachinery. His main focus is
the hydraulic design of turbines and pumps, both with CFD and model testing. At present he is
technical director of ASTR, department for hydraulic engineering and lab.
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Large Kaplan Units case study Xayaburi